Mobility and Sustainability.

Process of Scrap Vehicle Recovery

The first step of the recovery cycle is to hand in the scrap vehicle to a certified dismantling operation.
After the vehicle data have been recorded, first of all the battery is removed and the airbags fired for safety reasons. This if followed by dismantling of the tyres and the removal of all operating fluids (fuel; engine, gear, power steering and shock absorber oil; air conditioning refrigerants as well as brake and coolant fluids).

Fig.: Removal of all Operating Fluids using Modern Technology (Photo: MAS Fahrzeugrecycling GmbH, Etzin)

The expert dismantling process comprises many components and modules that are sold directly as used spare parts or act as the basis for the manufacture of replacement parts. Catalytic converters and panes of glass are also removed. Depending on the economic conditions and the demand on the market for recyclates, plastic parts are dismantled for material recycling.

Fig.: Used Spare Parts/Starter (Photos : MAS Fahrzeugrecycling GmbH, Etzin)

Fig.: Drained Bodywork in a High-Rack Warehouse (Photo: RETEK AG, Ihlow)

The remaining bodywork is crushed and taken to a shredder. This grinds the remaining bodywork into pieces just a few centimetres in size and thus enables the remaining metallic materials to be recycled. This means that almost 80 % of the scrap vehicle have been recovered.

The remainder of around 20 %, also called shredder residue, can be further treated with new technologies and then also largely recycled. In this way, the surrendered scrap vehicle achieves the high recovery rate of at least approx. 95 %. Together with technology partners, VW has developed a new treatment process for this. The technology, called the "VW-SiCon Process", intelligently combines various tried and tested treatment stages. Several fractions are thus gained from the formerly worthless shredder residues; these then find an environmentally sound and economically practical use, mainly in feedstock recycling methods. Scrap vehicle recovery thus achieves an overall recovery rate of 95% and thus contributes greatly to the protection of primary raw materials. The VW-SiCon process has already been awarded two environmental prizes for this.

Fig.: Process Stages of Scrap Vehicle Recovery

Manufacture of Replacement Parts

The highest level of recycling is the reuse of a component. That is why Volkswagen makes "as new" original replacement parts from used car parts, naturally with the same guarantee as for new parts. To date, for example, over 7.2 million engines and 2.2 million gearboxes have been made of used aggregates. The entire range of replacement parts currently comprises over 8,000 items from 42 product groups.

Recycling of Catalytic Converters

Residues from the production of catalytic converters as well as faulty and used catalytic converters are subjected to a high-quality recycling process. Here, as well as the ferrous metals, the valuable precious metals platinum, palladium and rhodium are recovered and used for the manufacture of new catalytic converters. This process is not only a win for the environment, but also ensures the raw material supply, to the benefit of Volkswagen and its customers.

Fig.: Typical Catalytic Converter Scrap